Laser Line Patterning of Continuous Coatings Without Melting
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Solution Overview
Problem
Current methods for spatially modulating the properties of coatings on substrates, such as optical and electrical conduction properties, are inefficient, difficult to scale, and require complex and costly processes, limiting their industrial application and production rates.
Innovation Solution
A process involving laser radiation heat treatment, where a continuous coating is irradiated with a focused laser line, and the power is temporally modulated as the substrate moves relative to the laser line, allowing for spatial modulation of coating properties without melting the coating, enabling high-resolution patterns on large substrates with rapid production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to spatially modulate coating properties, then manufacturing complexity and cost increase, but production rates and scalability remain limited
Solution Approach 1:
The patent replaces mechanical patterning methods (masks, stencils, sequential deposition) with a laser-based thermal field approach. The laser line scans across the substrate, using optical energy to locally modify coating properties through controlled heating, thereby achieving spatial modulation without mechanical intervention. This substitution resolves the contradiction by enabling both high manufacturing ease and high production rates simultaneously.
Solution Approach 2:
The patent employs periodic modulation of the laser line power as it scans across the substrate. By varying the laser power in a periodic manner (on/off cycles or amplitude modulation), the coating properties are spatially modulated along the scan direction. This periodic action enables continuous processing at high speed while achieving the desired patterned properties, resolving the contradiction between manufacturing ease and productivity.
2Manufacturing precision
If high-resolution patterns are achieved through conventional methods, then manufacturing complexity increases, but production rates decrease
Solution Approach 1:
The patent transitions from point-by-point or line-by-line sequential processing to a scanning laser line approach that processes an extended area simultaneously. The laser line has a finite width and scans across the substrate, effectively adding a spatial dimension to the processing. This allows high-resolution patterns to be achieved while maintaining high production rates, as the entire line width is processed in parallel rather than sequentially.
Solution Approach 2:
The patent uses dynamic control of the laser line parameters (power, scanning speed, focal position) to achieve high-resolution patterns at high speed. The laser power is dynamically modulated during scanning, and the focal position can be dynamically adjusted to optimize resolution. This dynamic control enables the system to adapt to different pattern requirements while maintaining high productivity, resolving the contradiction between manufacturing precision and production rate.
3Ease of manufacture
If masks are used during deposition to create patterns, then manufacturing complexity and cost increase, but substrate cleanliness requirements become more stringent
Solution Approach 1:
The patent applies the laser treatment after the coating has been deposited as a continuous uniform layer. The patterning action is performed as a preliminary finishing step rather than during deposition. This eliminates the need for masks during deposition, simplifying the manufacturing process and reducing substrate cleanliness requirements, while still achieving the desired patterned properties through post-deposition laser modification.
4Productivity
If laser power is increased to achieve high production rates, then coating melting occurs, but pattern resolution decreases
Solution Approach 1:
The patent optimizes the laser parameters (power, scanning speed, pulse duration, focal position) to achieve the desired balance between production rate and pattern resolution. By carefully controlling the laser power and scanning speed, the processing time per unit area is reduced, preventing coating melting while still achieving the desired pattern properties. This parameter optimization resolves the contradiction by enabling high productivity without sacrificing manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves high-resolution, spatially modulated patterns on coatings with increased production rates, maintaining the coating's continuity and applicability to large substrates, while avoiding the need for high temperatures, thus being suitable for both glass and polymeric materials.
Implementation Method 1
where the coating before heat treatment at least partially absorbs the laser radiation
Implementation Method 2
heat treatment, by means of laser radiation, of a continuous coating deposited on the substrate
Data Source
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AI summary
The invention relates to a method for producing a substrate provided with a coating, where the coating comprises a pattern with a spatial modulation of at least one property of the coating, said method comprising a step of heat treatment by means of laser radiation of a continuous coating deposited on the substrate. The step of heat treatment is such that the substrate is irradiated with the laser radiation focussed on the coating in the form of at least one laser line, maintaining the continuous coating and without melting the coating, and a relative movement of the substrate and the laser line focussed on the coating is imposed in a direction (X) transverse to the longitudinal direction (Y) of the laser line, temporally modulating, during said relative movement, the power (Plas) of the laser line according to the speed (v) of relative movement and the dimensions of the pattern in the direction (X) of relative movement.